Background of the Invention
[0001] The present invention idea relates to amine-based hydrophobically modified alkylene
oxide urethane polymers as rheology modifiers, which are especially useful in architectural
coatings.
[0002] Rheology modifiers are typically designed to impart desirable rheological properties
to coating formulations over a wide shear rate range.
US Patent No. 7,741,402 discloses ethylene oxide urethane polymers modified with hydrophobes that contain
organic bases such as secondary or tertiary amines (amine-modified HEURs), the presence
of which provides for viscosity control through a pH trigger. When the pH of the HEUR
composition is sufficiently low with respect to the pK
a of the incorporated base, the basic groups are protonated and the viscosity is relatively
low; when the pH is sufficiently high, associative thickening occurs. Thus, incorporation
of basic hydrophobes into the HEUR polymer allows relatively high concentration of
polymer to be dissolved in water at low pH; once the solution is added to the high
pH environment of paint coatings, the base is deprotonated and the associative thickening
mechanism activated.
[0003] Amine-modified HEURs can be sensitive to the pH of the paint formulation to which
it is added. For example, the pH of the formulation, through time and heat aging,
may decrease to a level below a critical pH conducive to associative thickening, thereby
resulting in a poorer formulation; consequently, it would be desirable to discover
a hydrophobe, more particularly an amine-based hydrophobe, that preserves the desired
viscosity of the formulation in face of pH-lowering mechanisms.
Summary of the Invention
[0004] The present invention addresses a need by providing, in a first aspect, a a hydrophobically
modified alkylene oxide urethane polymer with pendant or end-capping tertiary amine
groups, the conjugate acids of which have a pK
a in the range of 4.5 to 6.5, wherein the tertiary amine groups are monobenzyldi(alkyleneoxy)amino
groups.
[0005] In a second aspect, the present invention is a composition comprising an aqueous
dispersion of a hydrophobically modified alkylene oxide urethane polymer with pendant
or end-capping protonated tertiary amine groups having a pK
a in the range of 4.5 to 6.5, wherein the tertiary amine groups are monobenzyldi(alkyleneoxy)amino
groups.
[0006] The polymer of the present invention is useful as a rheology modifier for paint formulations
formulated over a wide pH range and is more stable to heat aging than higher pK
a amine-modified HEURs.
Brief Description of Drawings
[0007] Fig. 1 is a viscosity versus pH profile of aqueous dispersions of HEURS containing
pendant or end-capping tertiary amine groups.
Detailed Description of the Invention
[0008] The present invention, in its various aspects, is as set out in the accompanying
claims. The hydrophobically modified alkylene oxide polyurethane is characterized,
in part, by hydrophilic polyalkylene oxide groups, examples of which include hydrophilic
polyethylene oxide, hydrophilic polyethylene oxide/polypropylene oxide copolymers,
and hydrophilic polyethylene oxide/polybutylene oxide copolymers. A preferred hydrophobically
modified alkylene oxide polyurethane is a hydrophobically modified ethylene oxide
polyurethane (HEUR). It is is further characterized by the inclusion of hydrophobic
pendant or end-capping tertiary amine groups, the conjugate acids of which have a
pK
a in the range of 4.5 to 6.5, preferably in the range of 5.2 to 6.5.
[0009] The pendant or end-capping hydrophobic amine groups are monobenzyldi(alkyleneoxy)amino
groups, as illustrated:

[0010] The hydrophobic polymer of the present invention is conveniently prepared by contacting
together under reactive conditions a) at least one hydrophobic compound which is a
dihydroxyalkylated tertiary amine characterized by having a conjugate acid with a
pK
a in the range of 4.5 to 6.5; b) a diisocyanate; and c) a water-soluble polyalkylene
glycol.
[0011] The hydrophobic compound has the following formula:

[0012] The pendant or end-capping hydrophobic groups are conveniently incorporated into
the polymer by reaction of the corresponding hydrophobic alcohol or diol with isocyanate
groups to form urethane linkages. When the hydrophobe is a mono-alcohol, the group
becomes an end-capping group; when the hydrophobe is a diol, the hydrophobe becomes
a pendant group.
[0013] The diisocyanate starting material is a C
4-C
20 aliphatic or aromatic diisocyanate. As used herein, "aliphatic" refers to saturated
or partially unsaturated linear-, branched-, or cycloaliphatic, or combinations thereof.
Examples of suitable diisocyanates include 1,4-tetramethylene diisocyanate, 1,6-hexamethylene
diisocyanate, 2,2,4-trimethyl-1,6-diisocyanatohexane, 1,10-decamethylene diisocyanate,
4,4'-methylenebis(isocyanatocyclohexane), 1,4-cyclohexylene diisocyanate, 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethylcyclohexane,
m- and p-phenylene diisocyanate, 2,6- and 2,4-toluene diisocyanate, xylene diisocyanate,
4-chloro-1,3-phenylene diisocyanate, 4,4'-biphenylene diisocyanate, 4,4'-methylene
diphenylisocyanate, 1,5-naphthylene diisocyanate, and 1,5-tetrahydronaphthylene diisocyanate.
[0014] A water-soluble polyalkylene glycol refers to water-soluble polyethylene oxides,
water-soluble polyethylene oxide/polypropylene oxide copolymers, and water-soluble
polyethylene oxide/polybutylene oxide copolymers. As used herein, the term propylene
oxide refers to either a polymer having -(OCH
2CH
2CH
2)- and/or -(OCH(CH
3)CH
2)- repeating groups.
[0015] Preferred water-soluble polyalkylene oxides are polyethylene glycols, particularly
polyethylene glycols having a weight average molecular weight in the range of from
4000, more preferably from 6000, and most preferably from 7000 to 20,000, more preferably
to 12,000 and most preferably to 9000 Daltons. An example of a suitable polyethylene
glycol is PEG 8000, which is commercially available as CARBOWAX™ 8000 Polyethylene
Glycol (a trademark of The Dow Chemical Company ("Dow") or an affiliate of Dow, Midland,
MI).
[0016] The water soluble polyalkylene oxides may, alternatively, be linked with polyfunctional
groups other than polyisocyanates to form non-urethane compositions that can benefit
by tertiary amine-modification as described herein. Examples of suitable alternative
linker groups include epihalohydrins, gem dihalides, and aminoplasts.
[0017] In a second aspect, the present invention is a composition comprising an aqueous
dispersion of a hydrophobically modified alkylene oxide urethane polymer with pendant
or end-capping protonated tertiary amine groups having a pK
a in the range of 4.5 to 6.5. The protonated tertiary amine groups (i.e., the conjugate
acid of the tertiary amine groups) are conveniently prepared by adding the hydrophobically
modified alkylene oxide urethane polymer to sufficient amount of a sufficiently strong
Bronsted acid to protonate the amine groups. Examples of suitable acids include gluconic
acid, acetic acid, citric acid, lactic acid, phosphoric acid, sulfamic acid, hydrochloric
acid, sulfuric acid, and polyacrylic acids. The following structure illustrates the
protonated tertiary amine groups of this aspect of the invention:

[0018] The aqueous dispersion of this aspect of the present invention preferably includes
from 10 to 50 weight percent of the hydrophobically modified alkylene oxide urethane
polymer, based on the weight of water and the polymer.
[0019] The coating composition according to the present invention may further include one
or more of the following additives: Solvents; fillers; pigments, such as titanium
dioxide, mica, calcium carbonate, silica, zinc oxide, milled glass, aluminum trihydrate,
talc, antimony trioxide, fly ash, and clay; polymer encapsulated pigments, such as
polymer-encapsulated or partially encapsulated opacifying pigment particles including
titanium dioxide, zinc oxide, or lithopone polymers; polymers or polymer emulsions
adsorbing or bonding to the surface of pigments such as titanium dioxide; hollow pigments,
including pigments having one or more voids; dispersants, such as aminoalcohols and
polycarboxylates; surfactants; defoamers; preservatives, such as biocides, mildewcides,
fungicides, algaecides, and combinations thereof; flow agents; leveling agents; and
additional neutralizing agents, such as hydroxides, amines, ammonia, and carbonates.
[0020] For example, the coatings composition may include polymer-encapsulated opacifying
pigment particles comprising i) opacifying pigment particles, such as titanium dioxide
particles, having a diameter in the range of 100 nm to 500 nm and an index of refraction
of at least 1.8; ii) an encapsulating polymer, and iii) a polymeric dispersant for
the encapsulated opacifying pigment particles and the polymer. Such polymer-encapsulated
opacifying pigment particles are described, for example, in U.S. Patent Publication
US 2010/0298483 A1. In another example, the coating composition may include polymer-encapsulated opacifying
pigment particles as described in
WO 2007/112503A1.
Examples
[0021] The following examples are for illustrative purposes only and are not intended to
limit the scope of the invention.
Intermediate 1 (not according to the invention)
[0022] Dibenzylamine (424 g), butyl glycidyl ether (307 g) and water (20 g) were heated
to reflux (105-115 °C) under a nitrogen atmosphere in a round bottom flask equipped
with a condenser and mechanical stirrer. After 6 h, the mixture was cooled to 30 °C.
Product was isolated after water and residual butyl glycidyl ether were removed
in vacuo (15 mm Hg) over a temperature range of 30-150°C.
Intermediate 2
[0023] N-Benzylethanolamine (200.6 g) and 2-ethylhexyl glycidyl ether (250.0 g) were heated
to 100 °C under a nitrogen atmosphere in a round bottom flask equipped with a condenser
and mechanical stirrer. After stirring for 3 h, the reaction mixture was cooled to
room temperature. The resulting diol product was used without further purification.
[0024] Example 1 (not according to the invention) - Preparation of HEUR Polymer based on N-Benzyldiethanolamine,
Intermediate 1, and Bis-(4-isocyanotocyclohexyl) methane CARBOWAX™ 8000 Polyethylene
Glycol (molecular weight 8200; 1842.3 grams) was heated to 110°C under vacuum in a
batch melt reactor for 2 h. N-Benzyldiethanolamine (32.97 g) and Intermediate 1 (46.47
g) were added to the reactor and allowed to mix for 5 min. Desmodur W diisocyanate
(113.6 g) was then added to the reactor and mixing was continued for 5 min. Bismuth
octoate solution (28%, 4.61 grams) was then added to the reactor. The mixture was
then held at 110°C with stirring for 12 min. The resulting molten polymer was removed
from the reactor and cooled. Following the procedure described herein, the pK
a for this polymer was found to be 5.5.
Example 2- Preparation of HEUR Polymer based on Intermediate 2
[0025] CARBOWAX™ 8000 Polyethylene Glycol (molecular weight 8200; 1737.4 g) was heated to
110°C under vacuum in a batch melt reactor for 2 h. After removing the vacuum, Intermediate
10 (69.2 g) was added to the reactor and allowed to mix for 5 min. IPDI (83.57 g)
was then added to the reactor and mixing was continued for 5 min. Bismuth octoate
solution (28%, 4.34 g) was then added to the reactor. The mixture was then held at
110 °C with stirring for 10 min. The resulting molten polymer was removed from the
reactor and cooled. Following the procedure described herein, the pK
a for this polymer was found to be 5.2.
Comparative Example 1 - Preparation of HEUR Polymer based on Bis(2-ethylhexyl)aminoethanol
[0026] CARBOWAX™ 8000 Polyethylene Glycol (molecular weight 8200; 1709.8 g) was heated to
110°C under vacuum in a batch melt reactor for 2 h. The reaction mixture was then
cooled to 85 °C, after which time bis(2-ethylhexyl)aminoethanol (91.58 g) was added
and stirring continued for 5 minutes. IPDI (78.44 g) was then added to the reactor
and mixing was continued for 5 min. Bismuth octoate solution (28%, 4.27 g) was then
added to the reactor. The mixture was then held at 85 °C with stirring for 20 min.
The resulting molten polymer was removed from the reactor and cooled Following the
procedure described herein, the pK
a for this polymer was found to be 7.5.
Comparative Example 2 - Preparation of HEUR Polymer Based on Bis(2-ethylhexyl)aminoethanol
[0027] CARBOWAX™ 8000 Polyethylene Glycol (molecular weight 8200; 1844.0 g) was heated to
110°C under vacuum in a batch melt reactor for 2 h. Intermediate 8 (31.54 g) and Intermediate
9 (19.74 g) were added to the reactor and allowed to mix for 5 minutes. IPDI (76.38
grams) was then added to the reactor and mixing was continued for 5 minutes. Bismuth
octoate solution (28%, 4.40 grams) was then added to the reactor. The mixture was
then held at 110°C with stirring for 12 min. The resulting molten polymer was removed
from the reactor and cooled.. Following the procedure described herein, the pK
a for this polymer was found to be 7.1
Comparative Example 3 - Preparation of HEUR Polymer Based on N-benzyl-N-methylethanolamine
[0028] A mixture of CARBOWAX™ 8000 Polyethylene Glycol (150 g) and toluene (340 g) were
added to a vessel and dried by azeotropic distillation. The mixture was cooled to
90 °C whereupon Desmodur W (7.54 g) was added followed by stirring for 5 min. Dibutyltin
dilaurate (0.21 g) was added and the mixture stirred for an additional 1 h. After
cooling to 80 °C, N-benzyl-N-methylethanolamine (4.32 g) was added to the mixture
and stirring was continued for an additional 1 h. The mixture was cooled to 60 °C
and the polymer was isolated by way of rotary evaporation. This thickener showed unacceptable
thickening efficiency as illustrated by Fig. 1, which shows that a 20% solution by
weight had to be prepared to show any significant difference in viscosity. Following
the procedure described herein, the pK
a for this polymer was found to be 7.1.
Preparation of an Aqueous Dispersion of the Hydrophobic Polymer and pKa Determination
[0029] An acidic aqueous dispersion of the hydrophobic polymer is conveniently prepared
by dispersing the hydrophobic polymer into water and a suitable acid to form a homogeneous
mixture. The pK
a of the conjugate acid of the pendant or end-capping tertiary amine groups can then
be measured by the following general method: ∼25 g ofhydrophobically modified polymer
(thickener) is dispersed homogeneously in ∼975 g of water and sufficient phosphoric
acid to provide 1000 g of aqueous composition with a thickener solids content of 2.5%
and a pH = 4. A mechanical stirrer, a pH meter probe, and a Brookfield viscometer
are mounted over the vessel to provide simultaneous agitation, and pH and viscosity
measurement of the aqueous dispersion. Temperature is held at ∼25 °C and the stirrer
is turned off while pH and viscosity measurements are recorded.
[0030] The pH of the aqueous composition is increased stepwise with 10% aqueous ammonia
until a maximum pH of ∼10.5 is obtained. After each aliquot of ammonia is added, the
composition is stirred for 5 minutes, and pH and viscosity are measured. Viscosity
in centipoise is measured at 60 rpm and spindle #3 of the Brookfield LV viscometer,
although more viscous titrations may require 60 rpm or lesser speeds with spindle
#4 of the Brookfield LV viscometer to keep the viscometer readout on scale. The viscosity
is plotted on a linear scale versus the pH on a linear scale. At low and high pH values,
the viscosity of the aqueous composition is relatively independent of pH. At intermediate
pH values near or at the pK
a, the viscosity is dependent upon pH. The viscosity value at the high pH end of titration
curve where the viscosity starts to become relatively independent of pH is assigned
as the maximum viscosity value. The point on the titration curve corresponding to
half of the maximum viscosity value is defined as the pK
a of the conjugate acid of pendant or end-capping tertiary amine groups and, by extension,
the pK
a of the mono- or dihydroxyalkylated tertiary amine used to make these hydrophobic
groups.
Detailed Description of the Figure
[0031] Fig. 1 shows a pH versus viscosity profile of aqueous dispersions of Example 1 (Ex
1, 2.0 wt% x 0.50) and comparative examples 1 (C1, 2.5 wt. % x 0.01), 2 (C2, 2.5 wt.
% x 0.10), and 3 (C3, 20 wt%), by which pK
a values are measured. The figure illustrates that the viscosities of the comparative
examples are all above 7.0. As the heat-age stability studies below show, Example
1, with a pK
a of 5.5, demonstrates a dramatic improvement in heat age stability as compared to
the higher pK
a thickeners not within the scope of this invention.
Heat Age Stability Studies
[0032] Heat age stabilities of thickened paints were evaluated in a satin white formulation.
The satin white formulation had a pigment volume concentration of 40.5% and a total
solids concentration of 38.0% by volume. The major binder in the formulation was ROVACE™
661 Poly(vinyl acetate) Binder (A Trademark of The Dow Chemical Company or its Affiliates,
30.3 weight % of wet binder of the weight of wet paint formulation). The formulation
also contained RHOPLEX™ SG-10M Acrylic Copolymer Emulsion (A Trademark of The Dow
Chemical Company or its Affiliates, 4.1 weight % of wet emulsion of the weight of
wet paint formulation). Paints comprising poly(vinyl acetate) binders with an initial
pH of about 9 are known to decrease in pH upon aging because of hydrolysis of the
acetate group. An initial paint pH of about 9 can facilitate colloidal and biocide
stability of the paint. Paint pH typically decreases to about pH 7 upon aging whereupon
the rate of hydrolysis slows dramatically. Heat aging is typically employed in lab
studies to accelerate the effects of paint aging. A large viscosity drop upon aging
is undesirable.
[0033] Table 1 shows heat age stability of thickeners of the present invention compared
to thickeners having high pK
a amine hydrophobes (Comparative Examples 1 and 2) and a non-acid suppressible thickener
(ACRYSOL™ SCT-275). Use Level (%) is the concentration of thickener used in the paint.
The concentration is expressed as the weight percent of dry active thickener per wet
weight of final paint. Example 1-2 thickeners and the Comparative Example thickeners
were added as 16 weight % active thickener dispersions in water. These aqueous thickener
dispersions also contained 3% wet weight of lactic acid, as supplied. The lactic acid
obtained from Aldrich Chemical was supplied at 85% solids. The thickener dispersions
were made by combining the dry thickener solid, water and lactic acid in a sealed
plastic 50-mL centrifuge tube, and slowly rotating the mixture for two days to fully
homogenize the thickener solid. The HEUR of Comparative Example 3 is a very poor thickener
and was not suitable for making an acceptable paint. Therefore, heat age stability
testing was not conducted on this comparative example.
[0034] pH1 is the initial pH of the paint measured one hour after each paint was formulated.
Ammonia was used to adjust the pH to the value shown.
[0035] Stormer1 is the initial Stormer viscosity, in Krebs Units, of the paints measured
at 25 °C in half pint metal cans. Stormer1 was measured 24 h after paint formulation.
The paint was maintained at 25 °C during this equilibration time. Just prior to measuring
the Stormer viscosity, the paints were poured into a half pint metal can and stirred
with a tongue depressor for 20 s. The Krebs viscometer is a rotating paddle viscometer
that is compliant with ASTM-D562. KU viscosity was measured on a Brookfield Krebs
Unit Viscometer KU-1+ available from Brookfield Engineering Labs (Middleboro, MA,
USA).
[0036] pH2 is the paint pH after the paints were stored for 2 weeks in a 60 °C oven. The
paints were stored in sealed metal cans during the heat aging process.
[0037] Stormer2 is the final Stormer viscosity, in Krebs Units, of the heat aged paints
measured at 25 °C in half pint metal cans. Just prior to measuring the Stormer viscosity,
the paints were stirred vigorously with a tongue depressor for 20 s.
[0038] Delta Stormer, in Krebs Units, is equal to Stormer2 minus Stormer1. A value of Delta
Stormer that is less negative, that is, closer to zero, is desirable.
[0039] ACRYSOL™ SCT-275 refers to ACRYSOL™ SCT-275 Polyurethane Associative Thickener (A
Trademark of The Dow Chemical Company or its Affiliates), the hydrophobes of which
are not acid suppressible (they do not contain amine groups). The as-is viscosity
of the product is suppressed by the use of a butyl carbitol-water co-solvent mixture.
[0040] Paints thickened with Examples 1-7 exhibit much less viscosity drop upon aging than
paints thickened with Comparative Examples 1 and 2. The viscosity drops upon aging
exhibited by paints thickened with Examples 1-7 are similar to or better than the
viscosity drop of a paint thickened with ACRYSOL™ SCT-275 thickener; however, this
commercial thickener disadvantageously contributes VOC to the paint.
Table 1 - Heat Age Stability Study
| Thickener |
Use Level (%) |
pH1 |
Stormer1 |
pH2 |
Stormer2 |
Delta Stormer |
| Example 1 |
0.34 |
9.1 |
103 |
8.2 |
100 |
-3 |
| Example 2 |
0.41 |
9.1 |
94 |
8.1 |
82 |
-12 |
| Comparative Example 1 |
0.51 |
9.1 |
95 |
8.1 |
73 |
-22 |
| Comparative Example 2 |
0.40 |
9.0 |
111 |
8.2 |
81 |
-30 |
| ACRYSOL™ SCT-275 |
0.41 |
9.0 |
109 |
8.1 |
96 |
-12 |